According to the Centers for Disease Control and Prevention, U.S. employers lose an estimated $225.8 billion annually due to absenteeism. While there are several contributing factors, none are more costly than musculoskeletal disorders (MSDs), which account for $54 billion in annual losses.
The good news is that the problem is relatively easy and inexpensive to fix by creating a more ergonomic workplace. As a bonus, a safer assembly line also helps to increase productivity, boost employee morale and reduce workforce attrition. Studies demonstrate that ergonomic work environments increase productivity by 25 percent, lower absenteeism by 75 percent, and reduce workers’ compensation costs by up to 60 percent.
The key to better ergonomics is adjustability. Workbenches built from welded steel might seem like a good idea from a durability perspective, but they’re not very flexible. A better alternative is modular, adjustable, mobile workstations that adapt to employees’ natural movements, supporting continuous improvement while maintaining safety and efficiency.
Such workstations can be built using T-slot aluminum framing and modular accessories from 80/20, based in Columbia City, IN. With 80/20 components, engineers can design and assemble their own modular, adjustable workstations. They can change or tweak these workstations without sending them to a third-party for time-consuming and costly modifications. Instead, they can make the adjustments in-house. Most changes can be accomplished in less than an hour.
The main component of the 80/20 hardware line-up is the T-slot aluminum profile, a durable, high-strength, and visually appealing anodized aluminum beam that resists impacts and corrosion. These lightweight profiles have a high load-bearing capacity, are easy to cut, and simple to assemble.
The profiles can be reused as needed. Engineers can easily disassemble and reassemble workstations and other structures as requirements change. Hand tools are all that is needed.
A wide range of accessories and interchangeable components are available to create workstations, supply racks, material handling carts, and other structures. These include fasteners, connectors, joints, hinges, steel pipes, shelves, work surfaces, lighting, peg boards, storage bins, roller tracks, tool holders, tool rails, cup holders, and display holders. All components are designed to mount to the T-slot of the profile, so they can be positioned for optimal efficiency and ergonomics.
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Building a Workstation
There are five steps to designing and assembling a mobile, ergonomic workstation. They are defining the work zone, defining the workflow and work surfaces, organizing tools and consumables, ergonomic adjustments, and choosing the right casters.
The first—and most important—step is to define the work zones. This means identifying the most often used areas, the occasionally used areas, and the areas that are rarely used. What task will the assembler be performing at this workstation? What are the physical dimensions of the product the assembler will be working on? What essential tools and consumables are needed to perform the task? How should these be positioned to ensure the least amount of strain?
The goal is to configure the work zone in a way that minimizes reaching, limits repetitive movements, and ensures a natural, comfortable posture for the employee.
Next, engineers should define the workflow to ensure there is ample space for semi-finished parts to move freely within the workstation. Engineers should define entry and exit points for the product before and after the work task is completed.
If the assembler is working with electronic components, the workstation should be static-dissipative and properly grounded.
The next step is to organize tools and parts. From shadow boards and hooks to wire mesh, bins, plastic panels, and mounting plates, 80/20 offers an extensive selection of components for organizing the workstation.
From there, engineers should consider who will be using the workstation and how. Will the work be done sitting or standing? Will different people use the workstation over the course of a shift or workday? Again, accessories are available to enable assemblers to adjust the height of the worksurface to meet their needs.
Finally, engineers should consider their mobility requirements. If the workstation will need to be moved, a variety of casters are available to make the task easy. Some casters come with polyurethane wheels, while others have either rubber or nylon wheels. Some come with or without foot brakes. Some swivel; some don’t.
For more information on workstations and modular structural components, click https://8020.net or visit the company’s booth at The Manufacturing & Automation eXchange (MAX), which will be held March 25-26, 2026, at the Music City Center in Nashville, TN.
MAX was created in direct response to the shifts shaping manufacturing today: smart factories, integrated systems, workforce challenges, and the need for collaboration across disciplines. MAX merges the strengths of five manufacturing brands—ASSEMBLY, Quality, Adhesives & Sealants Industry, ISHN, and Packaging Strategies—to create one collaborative, unified event that reflects how modern manufacturers think, work, and solve.
Besides workstations and modular components, you’ll find more than 200 suppliers of automation, fastening tools, robotics, software, presses, adhesives, test and inspection technology, packaging equipment and safety products.
